Sterilization process transition method, product filling apparatus, and method and apparatus of cleaning and sterilizing the product filling apparatus

ABSTRACT

A sterilization process transition method of switching from an SIP process to a product sterilization process in an apparatus including piping that feeds a product into a filling machine through a heating sterilization part. The process sterilizes the piping before a filling operation, and the product sterilization process sterilizes the product to be filled. An F value is calculated from temperature and flowrate data on a fluid flowing in the heating sterilization part that are obtained from temperature sensors and flowmeters disposed in the product filling apparatus at predetermined time intervals. The temperature and flowrate at two or more predetermined positions in the product filling apparatus are adjusted from a set temperature and a set flowrate for the SIP process to a set temperature and a set flowrate for the product sterilization process while preventing the F value from becoming lower than a predetermined value.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a sterilization process transitionmethod for an apparatus that fills a container such as a PET bottle witha drink as a product, a product filling apparatus that performs thesterilization process transition method, and a method and an apparatusof cleaning and sterilizing the product filling apparatus.

Description of Related Art

When an aseptic drink filling apparatus fills a container such as abottle with a drink, not only does a product sterilization process inwhich the drink itself is sterilized to be aseptic have to be performed,but also product supply piping including a surge tank, a liquid feedingpipe, and filling nozzles in the product filling apparatus has to becleaned and sterilized to be aseptic in advance.

Conventionally, with regard to the drink itself flowing in the productsupply piping, the F value, which is a sterilization value, of theproduct is measured, and it is checked based on the historicalinformation on the F value whether or not the product is sterilized tosuch an extent that the quality of the product can be assured (seePatent Documents 1 and 2, for example).

With the product supply piping of the aseptic drink filling apparatus, aCIP (Cleaning in Place) process and an SIP (Sterilizing in Place)process are performed regularly or each time the kind of drink ischanged (see Patent Document 3, for example).

The CIP process is performed by passing a cleaner containing water andan alkali agent such as caustic soda as an additive through a flow pathfrom the pipe line of the product supply piping to the filing nozzles ofthe filling machine and then passing a cleaner containing water and anacid agent as an additive. The CIP process is performed by circulatingthe cleaner in the product filling path while keeping the cleaner at 80°C. in a heating sterilization part. The CIP process removes a residue ofthe previous product in the product supply piping, for example (seePatent Document 3, for example).

The SIP process is a process to sterilize the interior of the productsupply piping before the product filling operation is started, and isperformed by passing a heated steam or hot water through the productsupply piping cleaned by the CIP process described above, for example.The SIP process sterilizes the interior of the product supply piping andmakes it aseptic (see Patent Document 3, for example).

When the product is passed through the product supply piping after theCIP process and the SIP process are performed, a product sterilizationprocess is performed by heating and sterilizing the product in a heatingsterilization part (UHT: Ultra High-temperature) arranged along theproduct supply piping. Then, a container such as a bottle can be filledwith the sterilized product (see Patent Document 2, for example).

The CIP process, the SIP process and the product sterilization processtake a long time, and there are various known methods of reducing thetime. For example, as described in the patent documents listed below,there is a known method of performing the product sterilization processby determining the sterilization strength (F value) from thesterilization temperature and the flowrate.

PRIOR ART DOCUMENT Patent Document

Patent Document 1: Japanese Utility Model Laid-Open No. 61-50596

Patent Document 2: Japanese Patent Laid-Open No. 2007-215893

Patent Document 3: Japanese Patent Laid-Open No. 2007-22600

SUMMARY OF THE INVENTION Problems to be Solved by the Invention

By performing cleaning and sterilization of the product fillingapparatus and sterilization of the product in the manner describedabove, the quality of the product can be properly and quickly assured.

However, if different processes such as the CIP process, the SIP processand the product sterilization process are performed in sequence, thereis a problem that setting each process takes a very long time and it isdifficult to reduce the time required for preparation for each process.

For example, when the product sterilization process for the productfilling operation is started after the SIP process, in order totransition to the sterilization conditions for the manufacture, atemperature stabilization step needs to be performed by raising orlowering the temperature of the UHT heated for the SIP process to adesired set temperature or raising or lowering the flowrate of theproduct flowing in the product supply piping to a flowrate suitable forthe bottle to be filled, while maintaining the aseptic condition.Conventionally, in the temperature stabilization step, the temperatureor flowrate is controlled not to be out of the range between prescribedupper and lower limits over an extended time. This is intended toprevent the temperature or flowrate from being out of the range betweenthe prescribed upper and lower limits due to a rapid decrease intemperature. If the temperature or flowrate is out of the range betweenthe prescribed upper and lower limits, the aseptic condition of theproduct supply piping achieved by the SIP process cannot be maintained,so that the temperature or flowrate needs to be gradually reduced withcare in the adjustment thereof. Specifically, after the flowrate isadjusted, the temperature of each stage of the heating part or coolingpart of the UHT is carefully reduced. Setting each stage takes a longtime, so that the temperature stabilization step takes a long time forthe setting operation. In addition, if the temperature or flowrate goesout of the range between the prescribed upper and lower limits, theapparatus is poorly sterilized, and the SIP process needs to beperformed again.

With the trend of energy saving in recent years, the large amount ofthermal energy consumed in the temperature stabilization step performedin the transition from the SIP process to the product sterilizationprocess has come to be perceived as a problem. The long time requiredfor transition between processes also has come to be perceived as aproblem from the viewpoint of production efficiency of the product.

An object of the present invention is to provide a sterilization processtransition method and a product filling apparatus that can solve theseproblems.

According to a sterilization method that performs different processessuch as the CIP process, the SIP process and the product sterilizationprocess on the product supply piping of the product filling apparatus,when transitioning from the CIP process to the SIP process, a rinsingprocess is performed to rinse the cleaner used in the CIP process withaseptic water at room temperature. Therefore, as shown in FIG. 20, thetemperature of the heating sterilization part decreases and thus needsto be raised to a temperature for the SIP process before the SIP processis started. Thus, there is a problem that the CIP process and the SIPprocess and the transition between the processes take a very long time.Furthermore, there is another problem that a switching operationincluding change of the UHT holding tube (swing bend), replacement andinspection of filters at different positions, and disassembly andcleaning of the homogenizer is performed between the CIP process and theSIP process and between the manufacturing step and the CIP process, andthe switching operation takes a very long time.

As described above, according to the conventional cleaning andsterilization method, products cannot be manufactured during the CIPprocess or the SIP process, so that the operability of the productfilling apparatus decreases, and the products cannot be efficientlymanufactured. There is an intense demand for solving these problems.

The present invention has been devised to solve these problems, and anobject of the present invention is to provide a method and an apparatusof cleaning and sterilizing a product filling apparatus that canefficiently manufacture products with an increased operability.

Means for Solving the Problems

The inventor has studied management of the F value in order to reviewthe thermal energy required for switching from the SIP process to theproduct sterilization process or the required sterilization time for thedrink supply piping of the aseptic filling apparatus. Then, the inventorhas found that a setting change to a desired setting condition can bequickly made if the sterilization effect is determined in real timebased not only on the time after a desired temperature is reached butalso on an integration of the F value.

The present invention is based on the findings described above and ischaracterized by the following arrangements.

That is, a sterilization process transition method according to thepresent invention is a sterilization process transition method ofswitching from an SIP process to a product sterilization process in aproduct filling apparatus that includes product supply piping that feedsa product into a filling machine through a heating sterilization part,the SIP process being intended to sterilize the product supply piping inadvance before a product filling operation, and the productsterilization process being intended to sterilize the product to befilled, wherein an F value is calculated from temperature data andflowrate data on a fluid flowing in the heating sterilization part thatare obtained from a plurality of temperature sensors and flowmetersdisposed at arbitrary positions in the product filling apparatus atpredetermined time intervals, and the temperature and flowrate at two ormore of the plurality of predetermined positions in the product fillingapparatus are adjusted from a set temperature and a set flowrate for theSIP process to a set temperature and a set flowrate for the productsterilization process while preventing the F value from becoming lowerthan a predetermined value.

In the sterilization step transition method according to the presentinvention, it is preferable that a pressure of the product passingthrough the heating sterilization part is higher than a pressure of aheat source that heats the heating sterilization part or a pressure of acoolant that cools the heating sterilization part.

In the sterilization process transition method according to the presentinvention, the F value may be calculated according toF=∫ _(t) ₀ ^(t) ¹ 10^((T−Tr)/Z) dt  [formula 1]where T denotes an arbitrary sterilization temperature (° C.),10^((T-Tr)/Z) represents a fatality rate at an arbitrary temperature T,Tr denotes a reference temperature r (° C.), and Z denotes a Z value (°C.).

A product filling apparatus according to the present invention is aproduct filling apparatus comprising product supply piping that feeds aproduct into a filling machine through a heating sterilization part anda sterilization process transition unit that switches from an SIPprocess to a product sterilization process, the SIP process beingintended to sterilize the product supply piping in advance before aproduct filling operation, and the product sterilization process beingintended to sterilize the product to be filled, wherein the productfilling apparatus further comprises a controller that calculates an Fvalue from temperature data and flowrate data on a fluid flowing in theheating sterilization part that are obtained from a plurality oftemperature sensors and flowmeters disposed at arbitrary positions inthe product filling apparatus at predetermined time intervals, andadjusts the temperature and flowrate at two or more of the plurality ofpredetermined positions in the product filling apparatus from a settemperature and a set flowrate for the SIP process to a set temperatureand a set flowrate for any one of the product sterilization processeswhile preventing the F value from becoming lower than a predeterminedvalue.

A method of cleaning and sterilizing a product filling apparatusaccording to the present invention is a method of cleaning andsterilizing a product filling apparatus that includes product supplypiping that feeds a product into a filling machine through a heatingsterilization part, the method comprising a CIP process of removing aremaining foreign matter from a product or the like on an interior ofthe product supply piping and an SIP process of sterilizing the interiorof the product supply piping, wherein the CIP process and the SIPprocess are performed at the same time or in sequence without aninterruption between the CIP process and the SIP process.

In the method of cleaning and sterilizing a product filling apparatusaccording to the present invention, it is preferable that the SIPprocess ends when an F value reaches a predetermined value, the F valuebeing determined by substituting a value obtained from a thermometer inthe product supply piping into the following formula:F=∫ _(t) ₀ ^(t) ¹ 10^((T-121.1)/10) dt  [formula 2]where T denotes an arbitrary sterilization temperature (° C.),10^((T-121.1)/10) represents a fatality rate at an arbitrary temperatureT and corresponds to a heating duration (in minutes) at 121.1° C., whichis a reference temperature, and 10 denotes a Z value (° C.).

In the method of cleaning and sterilizing a product filling apparatusaccording to the present invention, it is preferable that rinse waterused to rinse a cleaner used in the CIP process has a sterilizationstrength determined from a sterilization temperature of the heatingsterilization part and a flowrate in the heating sterilization part.

In the method of cleaning and sterilizing a product filling apparatusaccording to the present invention, it is preferable that the methodcomprises a first manufacturing step of performing a filling step offilling a container with the product while performing a productsterilization process after the SIP process, and a second manufacturingstep including the CIP process and the SIP process for manufacturing aproduct different from that manufactured in the first manufacturingstep, and the first manufacturing step and the second manufacturing stepare performed without reducing the temperature of the heatingsterilization part to be equal to or lower than a set temperature of theCIP process.

In the method of cleaning and sterilizing a product filling apparatusaccording to the present invention, it is preferable that the productsupply piping is provided with a filtering device that filters theproduct, and the filtering device includes a switching step of switchingbetween a first filtering device used in at least the firstmanufacturing step and a second filtering device used in the secondmanufacturing step.

In the method of cleaning and sterilizing a product filling apparatusaccording to the present invention, it is preferable that the firstmanufacturing step includes a cleaning step of removing a remainingforeign matter on the second filtering device.

A product filling apparatus according to the present invention is aproduct filling apparatus that comprises product supply piping thatfeeds a product into a filling machine through a heating sterilizationpart and performs a CIP process of removing a remaining foreign matterfrom a product or the like on an interior of the product supply pipingand an SIP process of sterilizing the interior of the product supplypiping, wherein the CIP process and the SIP process are performed at thesame time or in sequence without an interruption between the CIP processand the SIP process.

Effects of the Invention

According to the present invention, in switching from the SIP processfor the product supply piping of the product filling apparatus to theproduct sterilization process, the F value is integrated in real time,and the temperature and the flowrate at two or more of a plurality ofpositions in the product filling apparatus are adjusted to the settemperature and the set flowrate for the subsequent productsterilization process while controlling the F value not to be lower thana predetermined value. Therefore, compared with prior art, thetransition from the SIP process for the product supply piping of theproduct filling apparatus to the product sterilization process can bemore properly and quickly achieved, the product filling operation can bestarted earlier, the time between productions of different products forchanging products can be reduced, and the production efficiency can beimproved.

According to the present invention, in the sterilization of the productfilling apparatus, after the CIP process using a cleaner, the SIPprocess is started without stopping the liquid feed pump, and theproduct supply piping is rinsed with aseptic water used in the SIPprocess. Therefore, the time required for transition from the CIPprocess to the SIP process can be reduced. In addition, water is notdischarged after the CIP process and reused for the subsequent SIPprocess, so that significant water conservation can be achieved. Inaddition, the rise in temperature required to perform the SIP process issmall (or zero), so that the required vapor energy can be substantiallyreduced.

According to the present invention, the sterilization by the SIP processis assured based on the actual sterilization strength (F value)determined from the sterilization temperature and the flowrate.Therefore, compared with the conventional sterilization method in whichtemperature and sterilization time are managed, the SIP process can bemore properly and quickly performed, the product filling operation canbe started earlier so that the time required for changing products canbe reduced, and the products can be efficiently manufactured.

According to the present invention, the first manufacturing stepincluding the CIP process, the SIP process and the product sterilizationprocess and the second manufacturing step in which the CIP process, theSIP process and the product sterilization process are performed toperform filling with a product different from that in the firstmanufacturing step are performed in succession, even if the productfilling apparatus manufactures products while changing the kind ofproduct, the product filling apparatus can efficiently manufactureproducts with an increased operability.

According to the present invention, the product supply piping includes afirst filtering device and a second filtering device. Therefore, thesefiltering devices can be efficiently washed by washing the secondfiltering device while the first filtering device is used in the firstmanufacturing step (see FIG. 5).

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram showing a product filling apparatus accordingto a first embodiment of the present invention.

FIG. 2 is a block diagram for illustrating an SIP process performed fora section of product supply piping in the product filling apparatusbetween a heating sterilization part (inclusive) and an aseptic surgetank (ACT) (exclusive).

FIG. 3 is a block diagram for illustrating the SIP process performed fora downstream-side piping section of the product supply piping in theproduct filling apparatus between the aseptic surge tank (ACT)(inclusive) and filling nozzles (inclusive).

FIG. 4 is a block diagram for illustrating production of a bottledproduct.

FIG. 5 is a block diagram showing a product filling apparatus thatperforms a cleaning and sterilization method according to a secondembodiment of the present invention.

FIG. 6 is a block diagram for illustrating a CIP process or SIP processperformed for an upstream-side piping section of product supply pipingbetween a heating sterilization part (inclusive) and an aseptic surgetank (exclusive) in the cleaning and sterilization method according tothe second embodiment of the present invention.

FIG. 7 is a block diagram for illustrating the CIP process or SIPprocess performed for a downstream-side piping section of the productsupply piping between the aseptic surge tank (inclusive) and fillingnozzles (inclusive) in the cleaning and sterilization method accordingto the second embodiment of the present invention.

FIG. 8 is a block diagram for illustrating the CIP process performed forthe entire product supply piping in the cleaning and sterilizationmethod according to the second embodiment of the present invention.

FIG. 9 is a block diagram for illustrating production of a bottledproduct.

FIG. 10 is a graph for illustrating a variation in temperature of theupstream-side piping section in the CIP process, the SIP process and amanufacturing step in the cleaning and sterilization method according tothe second embodiment of the present invention.

FIG. 11 is a graph for illustrating another variation in temperature ofthe upstream-side piping section in the CIP process, the SIP process andthe manufacturing step in the cleaning and sterilization methodaccording to the second embodiment of the present invention.

FIG. 12 is a graph for illustrating another variation in temperature ofthe upstream-side piping section in the CIP process, the SIP process andthe manufacturing step in the cleaning and sterilization methodaccording to the second embodiment of the present invention.

FIG. 13 is a graph for illustrating a variation in temperature of theupstream-side piping section in the manufacturing step in the cleaningand sterilization method according to the second embodiment of thepresent invention in a case where the CIP process and the SIP processare performed at the same time.

FIG. 14 is a graph for illustrating a variation in temperature of thedownstream-side piping section in the CIP process, the SIP process andthe manufacturing step in the cleaning and sterilization methodaccording to the second embodiment of the present invention.

FIG. 15 is a graph for illustrating another variation in temperature ofthe downstream-side piping section in the CIP process, the SIP processand the manufacturing step in the cleaning and sterilization methodaccording to the second embodiment of the present invention.

FIG. 16 is a graph for illustrating another variation in temperature ofthe downstream-side piping section in the CIP process, the SIP processand the manufacturing step in the cleaning and sterilization methodaccording to the second embodiment of the present invention.

FIG. 17 is a graph for illustrating another variation in temperature ofthe downstream-side piping section in the CIP process, the SIP processand the manufacturing step in the cleaning and sterilization methodaccording to the second embodiment of the present invention.

FIG. 18 is a graph for illustrating a variation in temperature in theCIP process, the SIP process and the manufacturing step in the cleaningand sterilization method according to the second embodiment of thepresent invention in a case where different products are manufactured insequence.

FIG. 19 is a diagram for illustrating details of a holding tube.

FIG. 20 is a graph for illustrating a variation in temperature in theCIP process, the SIP process and the manufacturing step in aconventional cleaning and sterilization method.

DETAILED DESCRIPTION OF THE INVENTION First Embodiment

In the following, a first embodiment of the present invention will bedescribed with reference to the drawings.

A structure of a product filling apparatus will be first described, anda method of sterilizing the apparatus and a method of switching betweenprocesses will then be described.

As shown in FIG. 1, the product filling apparatus includes a preparationunit 1 for a drink as a product and a filling machine 2 that fills abottle 4 with the drink. The preparation unit 1 and filling nozzles 2 ain the filling machine 2 are coupled to each other by product supplypiping 7. The filling machine 2 is surrounded by an aseptic chamber 3.

The preparation unit 1 prepares a drink such as tea or fruit juice bymixing ingredients in desired proportions. The preparation unit 1 is awell-known device and therefore will not be described in detail herein.

The filling machine 2 includes a large number of filling nozzles 2 aarranged around a wheel (not shown), which rotates at high speed in ahorizontal plane. As the wheel rotates, the filling nozzles 2 a rotate,and the drink is metered from the filling nozzles 2 a to bottles 4traveling below the filling nozzles 2 a at a velocity adjusted to thecircumferential velocity of the wheel. The filling machine 2 is also awell-known machine and therefore will not be described in detail herein.

In the product filling apparatus, along the path of the product supplypiping 7 from the preparation unit 1 to the filling machine 2, a balancetank 5, a heating sterilization part (hereinafter, referred to as UHT:Ultra High-temperature) 18, a manifold valve 8, an aseptic surge tank19, and a head tank 11 are disposed in this order from upstream todownstream of the flow of the drink.

The UHT 18 includes a first-stage heating portion 12, a second-stageheating portion 13, a holding tube 14, a first-stage cooling portion 15and a second-stage cooling portion 16, for example. The drink or watersupplied from the balance tank 5 is gradually heated while fed from thefirst-stage heating portion 12 to the second-stage heating portion 13until a target sterilization temperature is reached at an exit of thesecond-stage heating portion 13, kept at the sterilization temperaturefor a certain time in the holding tube 14, and then gradually cooledwhile fed from the first-stage cooling portion 15 to the second-stagecooling portion 16. The number of stages of heating portions or coolingportions can be increased or decreased as required. The UHT 18 mayinclude a homogenizer capable of automatic washing. The homogenizer ispreferably disposed between the first-stage heating portion and thesecond-stage heating portion or between the first-stage cooling portionand the second-stage cooling portion where the temperature of thecontent of the product is about 50 to 70° C. In the former case, acommon homogenizer can be used. In the latter case, however, an aseptichomogenizer is needed.

The balance tank 5, the manifold valve 8, the aseptic surge tank 19 andthe head tank 11 are well-known devices and therefore will not bedescribed in detail herein.

Next, a process path along which a CIP process and an SIP process areperformed will be described. As shown by a bold line in FIG. 2, anupstream-side piping section 7 a of the product supply piping 7, whichextends from the balance tank 5 to the manifold valve 8 through the UHT18, is provided with a feedback path 6 to form an upstream-side processpath, which is a circulation path for the CIP process or SIP process. Asshown by a bold line in FIG. 3, a downstream-side piping section 7 b,which extends from the manifold valve 8 to the aseptic surge tank 19,then to the head tank 11, then to the filling machine 2 and then back tothe manifold valve 8, is provided with a feedback, path 6 a to form adownstream-side process path, which is a circulation path for the CIP orSIP process.

The upstream-side piping section 7 a is provided with temperaturesensors 10 at positions including a position where the temperature isless likely to increase when hot water or the like is supplied to theinterior thereof. For example, the temperature sensors 10 can bedisposed at positions along the pipe line from the first-stage heatingportion in the UHT 18 to the manifold valve 8, such as positions in theUHT 18, a position at the outlet of the second-stage cooling portion 16,and a position at the inlet of the manifold valve 8. The temperaturesensors 10 are disposed at these positions. Temperature information fromthe temperature sensors 10 is transmitted to a controller 17.

The balance tank 5 can be any tank, such as an open tank for which thefilling temperature is prescribed to be lower than 100° C. or a tankthat is a first class pressure vessel to which a fluid at a temperatureof 100° C. or higher can be fed. When the open tank is used, a coolingunit is preferably provided between the manifold valve 8 and the balancetank 5.

As shown by the bold line in FIG. 3, the downstream-side piping section7 b of the product supply piping 7, which is located downstream of theupstream-side piping section 7 a and extends from the manifold valve 8to the filling machine 2 through the aseptic surge tank 19 and the headtank 11, is also provided with temperature sensors 10 at positionsincluding a position where the temperature is less likely to increasewhen heated steam or the like is supplied to the interior thereof. Forexample, the temperature sensors 10 can be disposed at positions alongthe pipe line from the aseptic surge tank 19 to the filling nozzles 2 a,such as a position in the vicinity of the outlet of the aseptic surgetank 19, a midway bent point, positions in the vicinities of the inletand outlet of the head tank 11, positions between a manifold 2 b and thefilling nozzles 2 a in the filling machine 2. The temperature sensors 10are disposed at these positions. Temperature information from thetemperature sensors 10 is transmitted to the controller 17. Thedownstream-side piping section 7 b, which extends from the fillingmachine 2 downstream of the aseptic surge tank 19 and the head tank 11to the manifold valve 8, is provided with the feedback path 6 a to forma circulation path for the CIP process or SIP process.

In the downstream-side piping section 7 b, a cup 9 is provided for anopening of each filling nozzle 2 a in the filling machine 2 for the CIPprocess or SIP process, and the cup 9 can be brought closer to andseparated from the filling nozzle 2 a. To perform the CIP process or SIPprocess, an actuator (not shown) puts each cup 9 on the opening at thetip end of the filling nozzle 2 a in the filling machine 2 to connect aleading end of a drain tube 20 to the opening of the filling nozzle 2 a.

The product supply piping 7 can include various switching valves, pumpsor other components in addition to the manifold valve 8 and the actuator(not shown), and these components are also controlled by the controller17.

Next, a method of sterilizing the product filling apparatus describedabove and a method of transition from the SIP process to a productsterilization process will be described with reference to FIGS. 2 to 4.

(1) When an operation button on a panel (not shown) of the controller 17is manipulated, the SIP process is performed for each of theupstream-side piping section 7 a and the downstream-side piping section7 b of the product supply piping 7 in a predetermined procedure (seeFIGS. 2 and 3). Before the SIP process is started, the manifold valve 8disconnects the upstream-side piping section 7 a and the downstream-sidepiping section 7 b from each other.

The SIP process for the upstream-side piping section 7 a and the SIPprocess for the downstream-side piping section 7 b can be performed insequence or in parallel with each other.

(2) First, water is fed from a water supply source (not shown) to theinterior of the circulation path through the balance tank 5. The wateris heated and sterilized in the UHT 18 while circulating in thecirculation path. In this way, the interior of the upstream-side pipingsection 7 a is sterilized.

(3) When the hot water is flowing in the upstream-side piping section 7a, the temperature sensors 10 disposed at different positions along theupstream-side piping section 7 a transmit temperature information to thecontroller 17 at regular time intervals. In this embodiment, it isassumed that the drink, which is a product liquid with which a bottle bis filled, has a pH of 4.6 or higher, a reference temperature Tr is121.1° C., and the Z value is 10° C.

When the temperature at each of the different positions raised byheating by the hot water reaches 121.1° C., the controller startscalculating the F value at the position according to the followingformula.F=∫ _(t) ₀ ^(t) ¹ 10^((T-121.1)/10) dt  [formula 3]where T denotes an arbitrary sterilization temperature (° C.),10^((T-121.1)/10) represents a fatality rate at an arbitrary temperatureT and corresponds to a heating duration (in minutes) at 121.1° C., whichis a reference temperature, and 10 denotes a Z value (° C.).

When the minimum F value of the F values calculated according to theformula described above reaches a target value, it is determined thatsterilization of the upstream-side piping section 7 a is completed,cooling water is supplied to the first-stage cooling portion 15 and thesecond-stage cooling portion 16, and the hot water is thereby cooled andcontinuously circulates, waiting for the start of sterilization of thedrink.

After the SIP process is completed, a temperature stabilization step isperformed to set the temperature and flowrate of the product supplypiping for the product sterilization process for the drink.

In the temperature stabilization step, the sterilization temperatures atthe positions in the UHT 18 and the time required for the water to passthrough the holding tube 14 are recorded at intervals of 1 second. Thetemperature data and the flowrate data are transmitted to the controller17 and stored. The temperature data and the flowrate data are preferablyrecorded for a period of time (for example, 200 seconds) that is threeor four times as long as the passing time of the holding tube 14 (forexample, 60 seconds).

The controller 17 calculates the sterilization strength (F value) fromthe passing time and the sterilization temperature for the UHT 18 (thetemperature at the outlet of the tube) in real-time. While monitoringthe calculated F value, the controller 17 adjusts the temperature andflowrate at each position (from the first-stage heating portion 12 tothe second-stage cooling portion 16) to the set value for the productsterilization process. The temperatures and flowrates at all thepositions from the first-stage heating portion 12 to the second-stagecooling portion 16 may be adjusted at the same time, or the temperaturesand flowrates at two or more of the positions from the first-stageheating portion 12 to the second-stage cooling portion 16, for example,may be adjusted at the same time.

If the pressure of the product passing through the UHT 18 is lower thanthe pressure of the heat source that heats the UHT 18 or the coolantthat cools the UHT 18, poor sterilization can occur. From the viewpointof safe back pressure, the pressure of the product passing through theUHT 18 is adjusted and set to be greater than the pressure of the heatsource that heats the UHT 18 or the coolant that cools the UHT 18.

According to the transition method, even if the sterilizationtemperature is momentarily lower than a lower limit, for example, anactual sterilization strength (F value) is assured, so that poorsterilization does not occur, and transition to the productsterilization process can properly and quickly occur.

In the formula for calculating the F value described above, thereference temperature Tr and the Z value can be changed according to thekind of the drink, which is a product liquid.

For example, when the pH of the product liquid is equal to or higherthan 4 and lower than 4.6, the reference temperature Tr can be 85° C.,and the Z value can be 7.8° C. When the pH of the product liquid islower than 4, the reference temperature Tr can be 65° C., and the Zvalue can be 5° C.

The values to be substituted into the formula described above can bechanged as appropriate according to the ease of development ofmicroorganisms, the temperature during distribution or the like of theproduct liquid, such as tea, mineral water or a chilled drink.

(4) After that, the product is fed from the preparation unit 1 to thebalance tank 5, and sterilization of the product is started. Once theproduct replaces the water, the upstream-side piping section 7 a isdisconnected from the feedback path, and sterilized product is stored inthe aseptic surge tank 19.

(5) When or before the SIP process for the upstream-side piping section7 a is started, the SIP process of the downstream-side piping section 7b including the aseptic surge tank 19 is started.

First, the cup 9 is put on the opening of the filling nozzle 2 a, thedrain tube 20 is connected to the filling nozzle 2 a, and then heatedsteam is supplied into the aseptic surge tank 19 and the head tank 11from a heated steam supply source (not shown).

The heated steam flows from the aseptic surge tank 19 to the fillingnozzles 2 a through the downstream-side piping section 7 b and heatsthose components before being discharged out of the filling machine 2through the drain tubes 20. If water is used for the SIP process for thedownstream-side piping section 7 b as with the SIP process for theupstream-side piping section 7 a, water is fed from the water supplysource (not shown) to the circulation path through the aseptic surgetank 19, and the water is heated and sterilized by a heating unit 21while circulating in the circulation path including the feedback path 6a. In this way, the downstream-side piping section 7 b is sterilized bythe warm water or hot water. The sterilization method based on the Fvalue is the same as the sterilization method for the upstream-sidepiping section 7 a and therefore will not be described in detail herein.

(6) While the heated steam is flowing in the downstream-side pipingsection 7 b, the temperature sensors 10 disposed at different positionsin the downstream-side piping section 7 b transmit temperatureinformation to the controller 17 at regular time intervals.

When the temperature raised by heating by the heated steam reaches121.1° C. at each position, the controller 17 calculates the F value atthe position according to the formula described above.

When the minimum F value of the calculated F values reaches a targetvalue, supply of the heated steam to the aseptic surge tank 19 and theinterior of the downstream-side piping section 7 b is stopped. The timerequired for the SIP for the downstream-side piping section 7 b issubstantially reduced compared with the conventional SIP process.

(7) After that, aseptic air or aseptic water is fed into thedownstream-side piping section 7 b to cool the interior of thedownstream-side piping section 7 b to, for example, room temperature.Then, the drain tubes 20 are disconnected. Furthermore, the actuator(not shown) removes the cups 9 from the openings of the filling nozzles2 a. The aseptic water may be fed from the product sterilizer that hasfinished the SIP process and is in the water operation in the standbystate. Alternatively, aseptic water from a bottle rinser (not shown) maybe received through the manifold valve 8 and used for cooling. Thecooling with the aseptic water can be started after the temperature ofthe tank after the SIP process has been reduced to below 110° C. bycooling with the aseptic air. The operation of supplying the asepticwater is performed by supplying aseptic air to prevent the pressure inthe tank from decreasing due to rapid cooling by using an intermittenttimer. After the temperature of the tank has decreased to about 30 to90° C., and the cooling is completed, the aseptic water remaining in thetank and the piping is blown off by aseptic air while maintaining apositive pressure, and the product is received. By additionally usingthe aseptic water, the downstream-side piping section 7 b can be cooledin a shorter time than when the downstream-side piping section 7 b iscooled only by air.

(8) After the SIP process for the aseptic surge tank 19 and thefollowing part of the downstream-side piping section 7 b ends, the drinkflowing from the heating sterilizing part 18 through the upstream-sidepiping section 7 a is stored in the aseptic surge tank 19, and thebottles 4 start being filled with the drink flowing therefrom throughthe downstream-side piping section 7 b.

The same temperature stabilization step as that for the upstream-sidepiping section 7 a described above can be performed for thedownstream-side piping section 7 b to achieve proper and quicktransition from the SIP process to the product sterilization process.

As shown by a bold line in FIG. 4, the product prepared in thepreparation unit 1 flows to the interior of the filling machine 2through the sterilized upstream-side piping section 7 a anddownstream-side piping section 7 b of the product supply piping 7, andthe bottles 4 as containers are filled with the drink through thefilling nozzles 2 a in the filling machine 2. The bottles 4 filled withthe product are capped by a capper (not shown) and then fed out of thefilling machine 2.

Second Embodiment

Next, a method of cleaning and sterilizing the product filling apparatusand a method of transition from the CIP process to the SIP processaccording to a second embodiment will be described with reference toFIGS. 6 to 19.

(CIP Process)

As shown in FIG. 6, when an operation button on a panel (not shown) ofthe controller 17 is manipulated, the CIP process is performed for eachof the upstream-side piping section 7 a and the downstream-side pipingsection 7 b of the product supply piping 7 in a predetermined procedure.The CIP process is performed by flowing an alkali cleaner that containsa mixture of water and an alkali agent such as caustic soda (sodiumhydroxide), potassium hydroxide, sodium carbonate, sodium silicate,sodium phosphate, sodium hydrochloride, a surface active agent or amixture thereof and is supplied from a cleaner supply source (not shown)and then flowing an acid cleaner that contains a mixture of water and anitrate-based or phosphate-based acid agent and is supplied from acleaner supply source (not shown).

The cleaners supplied from the cleaner supply sources (not shown) areactivated by the UHT 18 provided for the upstream-side piping section 7a and the heating unit 21 provided for the downstream-side pipingsection 7 b until a predetermined flowrate (1.5 m/s or higher, forexample) and a predetermined temperature (80° C., for example) arereached. The cleaners are constantly or intermittently supplied in aconstant amount from the respective cleaner supply sources (not shown)and remove drink residues from the previous operation on the interior ofthe product supply piping 7 while circulating in the product supplypiping 7. The cleaners may be discharged from the apparatus asappropriate. After the cleaners are passed for a predetermined time, arinsing step is performed to rinse the cleaners from the upstream-sidepiping section 7 a and the downstream-side piping section 7 b by passingwater therethrough, and then the CIP process ends. The completion of theCIP process is managed by the controller 17, and then transition to theSIP process occurs.

(SIP Process)

When the CIP process ends, the SIP process is performed for each of theupstream-side process path and the downstream-side process path in apredetermined procedure. Before the SIP process is started, the manifoldvalve 8 disconnects the upstream-side piping section 7 a and thedownstream-side piping section 7 b from each other.

The SIP process for the upstream-side process path and the SIP processfor the downstream-side process path can be performed in sequence or inparallel with each other.

First, the SIP process for the upstream-side process path will bedescribed. The liquid feeding pump used for the CIP process is notstopped, and water is fed from the water supply source (not shown) tothe interior of the circulation path through the balance tank 5. Thewater is heated and sterilized in the UHT 18 while circulating in thecirculation path. In this way, the interior of the upstream-side processpath is sterilized. In this step, since the liquid feeding pump is notstopped, the temperature of the UHT 18 raised and set in the CIP processdoes not decrease but is further raised to a temperature for the SIPprocess. Thus, the temperature drop during transition from the CIPprocess to the SIP process can be minimized (see FIG. 10). The detailsof the SIP process are the same as those in the first embodimentdescribed above and therefore will not be further described here.

When the minimum F value of the F values calculated according to theformula described above reaches a target value, it is determined thatsterilization of the upstream-side piping section 7 a is completed,cooling water is supplied to the first-stage cooling portion 15 and thesecond-stage cooling portion 16 to cool the hot water. The watersupplied to rinse the cleaner needs to be sterilized in the second-stageheating portion and the holding tube with the same or highersterilization strength as that required for the subsequent sterilizationof the product content. The sterilization strength is also constantlycalculated according to the above formula for determining the F value,and the F value is controlled to prevent the sterilization strength fromdecreasing. Alternatively, to maintain a fixed cleaning effect, therinse water used for cleaning may be aseptic water obtained bysterilizing water at a certain temperature for a certain time (so as tohave an F0 value equal to or higher than 4 or preferably equal to orhigher than 30, for example). Finally, it is checked by using aconductivity meter (not shown) or the like that there is no cleanerremaining in the piping. When the cleaner is replaced by water, supplyof water is stopped, and then the water continuously circulates, waitingfor the start of sterilization of the drink.

After the SIP process is completed, the temperature stabilization stepis performed to set the temperature and flowrate of the product supplypiping for the product sterilization process for the drink. In thisprocess, according to the sterilization temperature of the product to bemanufactured, the temperature of the UHT 18 raised in the SIP process isadjusted to a set temperature for the product sterilization process (seesymbols a to c in FIG. 10).

In the temperature stabilization step, the sterilization temperatures atthe positions in the UHT 18 and the time required for the water to passthrough the holding tube 14 are recorded at intervals of 1 second. Thetemperature data and the flowrate data are transmitted to the controller17 and stored. The temperature data and the flowrate data are preferablyrecorded for a period of time (for example, 200 seconds) that is threeor four times as long as the passing time of the holding tube 14 (forexample, 60 seconds), because such a length of time allows calculationof the actual strength of the sterilization of the content having passedthrough the holding tube 14.

As an alternative to the method of changing the F value to change thesterilization condition for the product according to the kind of theproduct, the sterilization condition may be changed by modifying thelength of the holding tube to adjust the length of time for which theproduct flows in the holding tube, thereby changing the sterilizationtemperature achieved by heating and the holding time. In this case, ifthe length of the holding tube is switched between two or more lengths(if the holding time is switched between 30 seconds and 60 seconds, forexample), sterilization conditions for various products can be achieved.Specifically, as shown in FIG. 19, the holding tube has a first pipeline 14 a, a second pipe line 14 b, a third pipe line 14 c and a fourthpipe line 14 d, and the total length of the holding tube can be adjustedby changing the combination of pipe lines by switching valves. Since theCIP process and the SIP process are performed at the same time or insequence, the length of the holding tube is preferably changed byautomatic valves while considering the safe back pressure. Furthermore,since the CIP process and the SIP process are performed at the same timeor in sequence, all the pipe lines of the holding tube can be cleanedand sterilized during the CIP process and the SIP process, and then, thepattern of the holding tube can be changed for the subsequentproduction. If there is a pipe line of the holding tube that is notused, after the SIP process, aseptic air can be supplied to the pipeline to keep the pipe line at a positive pressure in an asepticcondition. Alternatively, blow valves for drainage may be provided asthe end valves of the pipe lines of the holding tube, and the pressurein any pipe line that is not used may be reduced to zero. Alternatively,to prevent contamination by bacteria from outside, a vapor barrier maybe provided in the valves at the opposite ends of the pipe lines of theholding tube.

The step of rinsing the cleaner used in the CIP process that isperformed in transition from the CIP process to the SIP process can beperformed while increasing the temperature from the temperature at whichthe CIP process has been performed to the temperature at which the SIPprocess is to be performed as shown in FIG. 11. The rinse water used inthis rinsing step is heated in the UHT 18. To maintain the flowratewhile maintaining the aseptic condition in the rinsing step, a heatexchanger is preferably arranged before the balance tank 5 to reduce thecooling efficiency of the first-stage cooling portion 15 and thesecond-stage cooling portion 16 so that the temperature of the rinsewater entering the balance tank 8 is raised by the waste heat of therinse water discharged after rinsing. With such a configuration, even ifthe flowrate of the rinse water increases, the temperature of the rinsewater can be raised in the UHT 18 with reliability, so that the rinsingstep can be effectively performed in a shorter time. If water thatachieves the sterilization strength for the subsequent product is usedin the rinsing step, the rinsing step can be performed during the SIPprocess as shown in FIG. 12, or performed during the temperaturestabilization step following the SIP process as shown in FIG. 13. Whatis essential is that the cleaner is removed before the subsequentmanufacturing process is started. Furthermore, as shown in FIG. 13, theSIP process may be performed at the same time as the CIP process usingan alkali or acid that satisfies the sterilization temperaturecondition, and the manufacture of the subsequent product may be startedafter the interior of the piping is cleaned with aseptic water having atleast a sterilization strength prescribed for the subsequent product andthe cleaner is removed.

When or before the SIP process for the upstream-side piping section 7 ais started, the SIP process for the downstream-side process pathincluding the aseptic surge tank 19 is started. The SIP process for thedownstream-side process path is the same as that in the first embodimentdescribed above and therefore will not be described in detail here.

After the SIP process, aseptic air, aseptic water or the product is fedinto the downstream-side piping section 7 b to cool the interior of thedownstream-side piping section 7 b to, for example, room temperature asshown in FIG. 14. Then, the drain tubes 20 are disconnected.Furthermore, the actuator (not shown) removes the cups 9 from theopenings of the filling nozzles 2 a. The aseptic water may be fed fromthe product sterilizer that has finished the SIP process for thedownstream-side process path and is in the water operation in thestandby state. Alternatively, aseptic water (not shown) may be receivedthrough the manifold valve 8 and used for cooling. The cooling with theaseptic water can be started after the temperature of the tank after theSIP process has been reduced to below 110° C. (preferably to below 100°C.) by cooling with the aseptic air. The operation of supplying theaseptic water is performed under pressure by supplying aseptic air toprevent the pressure in the tank from decreasing due to rapid cooling byusing an intermittent timer. After the temperature of the tank hasdecreased to about 30 to 90° C., and the cooling is completed, theaseptic water remaining in the tank and the piping is blown off byaseptic air while maintaining a positive pressure, and the product isreceived. Alternatively, the cooling with the aseptic water may beomitted, and the product may be received immediately after the SIPprocess. By additionally using the aseptic water or the product forcooling as described above, the cooling can be achieved in a shortertime than when only air is used for cooling. The tank may be quicklycooled by supplying water or chiller water to a jacket of the tank inparallel with the cooling process described above. In the cooling stepwith the aseptic air in the SIP process, the blow valves may besequentially closed at positions where the cooling completiontemperature is reached to efficiently feed the cooling aseptic air toparts that are more difficult to cool.

If the drink to be manufactured next is a carbonated drink, the asepticwater is fed from a vicinity of the aseptic surge tank 19 to the headtank 11 and the filling nozzles 2 a through a carbonated drink line (notshown). On the carbonated drink line, the aseptic water is furthercooled (to 1 to 5° C.) by chiller water. Thus, the remaining heat fromthe SIP process can be completely removed, and foaming of the carbondioxide gas can be reduced during filling.

As with the case of the upstream-side piping section described above,the step of rinsing the cleaner used in the CIP process that isperformed in transition from the CIP process to the SIP process can beperformed while increasing the temperature from the temperature at whichthe CIP process has been performed to the temperature at which the SIPprocess is to be performed as shown in FIG. 15. If water that achievesthe sterilization strength for the subsequent product is used in therinsing step, the rinsing step can be performed during the SIP processas shown in FIG. 16, or performed during the cooling step following theSIP process as shown in FIG. 17. What is essential is that the cleaneris removed before the subsequent manufacturing process is started.Furthermore, as shown in FIG. 17, the SIP process may be performed atthe same time as the CIP process using an alkali or acid that satisfiesthe sterilization temperature condition, and the manufacture of thesubsequent product may be started after the interior of the piping iscleaned with aseptic water having at least a sterilization strengthprescribed for the subsequent product and the cleaner is removed.

To perform the SIP process for one of the upstream-side process path andthe downstream-side process path while performing the CIP process forthe other, a valve unit (with a vapor barrier) that allows steam to passtherethrough is preferably provided at an intersection between both thepaths in the manifold valve 8. In that case, even if a valve fails onone of the process paths, the risk of contamination of the interior ofthe other path is reduced. Alternatively, aseptic water can be usedinstead of the steam, or risks that may occur when a valve fails can bereduced by arranging a plurality of valves at the intersection of theprocess paths.

(Manufacturing Step)

After the SIP process for the aseptic surge tank 19 and the followingpart of the downstream-side piping section 7 b ends, the drink flowingfrom the UHT 18 through the upstream-side piping section 7 a is storedin the aseptic surge tank 19, and a manufacturing step of filling thebottles 4 with the drink flowing therefrom through the downstream-sidepiping section 7 b is started.

As shown by a bold line in FIG. 9, in the manufacturing step, theproduct prepared in the preparation unit 1 flows to the interior of thefilling machine 2 through the sterilized upstream-side piping section 7a and downstream-side piping section 7 b of the product supply piping 7,and the bottles 4 as containers are filled with the product through thefilling nozzles 2 a in the filling machine 2. The bottles 4 filled withthe product are capped by a capper (not shown) and then fed out of thefilling machine 2.

After the manufacturing step is completed, a second manufacturing stepcan be continuously performed to manufacture a different kind of productthan the previous product. In that case, the product supply piping 7needs to be cleaned and sterilized in the same processes as the CIP andSIP processes described above. However, before starting the CIP processof the second manufacturing step, a transition from the set temperatureof the UHT 18 in the first manufacturing step to the set temperature forthe CIP process is preferably made while performing the rinsing processof passing water, aseptic water or the like through the product supplypiping 7 (see FIG. 18).

As shown in FIG. 5, the product supply piping 7 is preferably providedwith a filtering device that filters out foreign matters in the product.The filtering device includes a first filtering device and a secondfiltering device arranged in parallel with each other, and the first andsecond filtering devices include a filtering member formed by a metalfilter, such as a stainless steel filter. The filtering device furtherincludes switching devices 23, 23 that automatically or manually switchbetween the first filtering device 22 a and the second filtering device22 b.

The first filtering device 22 a and the second filtering device 22 b arepreferably metal filters such as stainless steel filters and preferablydiffer in mesh fineness (mesh size). Preferably, for example, the firstfiltering device 22 a includes a metal filter of 100 to 400 mesh capableof removing finer foreign matters, and the second filtering device 22 bincludes a rougher metal filter of 10 to 100 mesh capable ofappropriately allowing flesh or pulp in the product to passtherethrough. By using filtering devices of different counts for thefirst filtering device 22 a and the second filtering device 22 b asdescribed above, foreign matters can be appropriately removed from eachindividual product to be manufactured.

In addition, the switching devices 23, 23 allow switching between thefirst filtering device 22 a and the second filtering device 22 b. Sincethe switching devices 23, 23 are provided, while the first filteringdevice 22 a is being used for filling with the product as shown in FIG.9, a cleaning step for the second filtering device 22 b can be performedto remove foreign matters from the second filtering device 22 b. Thus,during manufacture of the product, the filtering device can beefficiently cleaned and inspected. After the cleaning and inspection ofthe filters, the CIP process or the SIP process can be separatelyperformed. The switching devices 23 can be set to feed liquid to boththe first filtering device 22 a and the second filtering device 22 b. Inthat case, the CIP process or the SIP process for both the firstfiltering device 22 a and the second filtering device 22 b can beperformed at the same time. To reduce the risk of contamination of theproduct by a chemical agent or bacteria, the vapor barrier describedabove may be provided in the switching devices 23.

As shown in FIG. 5, for example, the filtering device may be disposedbetween the second-stage cooling portion (final cooling portion) 16 andthe manifold valve 8, rather than being disposed between the asepticsurge tank 19 and the head tank 11. A plurality of filtering devicesarranged in parallel with each other may be provided. The filteringdevice may be disposed at different positions, such as at a positionupstream of the balance tank 5 or at the tip ends of the fillingnozzles.

As described above, the first filtering device and the second filteringdevice are arranged in parallel with each other in the filtering device.Therefore, for example, filtering of the product can be performed by thefirst filtering device when the product is manufactured in the firstmanufacturing step, and can be performed by the second filtering devicewhen the product is manufactured in the second manufacturing step. Inthat case, while the product is being manufactured, the filtering devicethat is not used for filtering of the product is preferably subjected toa cleaning step of removing remaining foreign matters from themanufacturing step and an inspection operation of checking that theproduct does not contain rubber or metal foreign matters such as agasket residue. By performing the cleaning operation and the inspectionoperation during manufacture of the product as described above, acleaned filtering device can always be used after transition from thefirst manufacturing step to the second manufacturing step, and theoperability of the product filling apparatus is improved.

As described above with regard to the F value, sterilization conditionssuitable for various kinds of drinks can be satisfied by changing theflowrate and temperature of the fluid. However, in the CIP process, theflowrate is generally higher than in the manufacture of the product, sothat the temperature needs to be reduced in order to maintain the Fvalue, and thus it is difficult to achieve high temperature. For thisreason, when an existing facility is used, the CIP process can beperformed by reducing the flowrate as far as cleaning can be achieved.Alternatively, the existing facility may be improved by increasing thenumber of stages of heating portions or extending the length of theheating part to enhance the heating capability. Alternatively, thecooling capability during the CIP process may be reduced by adjustingthe settings of the cooling part so that the required sterilizationtemperature can be achieved by the heating part even if the flowrateincreases.

Although the present invention is configured as described above, thepresent invention is not limited to the embodiments described above, andvarious modifications can be made within the scope of the spirit of thepresent invention. The manifold 8 may be omitted, and the CIP and SIPprocesses for the components from the sterilizer to the filler can beperformed at the same time, and control of the temperature stabilizationstep described above can also be performed. Alternatively, the SIPprocess may be performed at the same time as the CIP process using analkali or acid that satisfies the sterilization temperature condition,and the manufacture of the subsequent product may be started after theinterior of the piping is cleaned with aseptic water having at least asterilization strength prescribed for the subsequent product and thecleaner is removed. Although the aseptic surge tank and the head tank inthe downstream-side piping section 7 b are subjected to the CIP processand the SIP process at the same time in the second embodiment describedabove, the aseptic surge tank and the head tank can be separatelysubjected to the CIP process and the SIP process. In that case, theamount of the liquid residing in the piping is reduced, and the CIPprocess and the SIP process can be completed in a shorter time.Although, in this specification, a shell and tube type heat exchangerhas been described as an example of the UHT (heating sterilization part)according to the present invention, the UHT is not limited to this type,and a plate type heat exchanger can also be used, for example.Furthermore, not only these indirect heating schemes but also directheating schemes can be used. Furthermore, the present invention has beendescribed with regard to the drink filling apparatus used for fillingwith a drink as a product, the product is not limited to drinks, and thedrink filling apparatus can be applied to filling with a medicine, afood, a liquid food or a drink containing a solid material. Furthermore,although the transition from the CIP process to the SIP process has beendescribed with regard to a case where the temperature for the SIPprocess is higher than the set temperature for the CIP process, the CIPprocess and the SIP process may be performed at the same temperature, orthe CIP process may be performed at a higher temperature than the SIPprocess. Although the water used for the CIP process is typically tapwater, when the CIP process is performed at a temperature higher than90° C. in order to perform the SIP process at the same time, pure wateris preferably used instead of tap water in order to prevent calciumdeposition.

The time interval at which the F value is measured and integrated is notlimited to 1 minute but can be 1 to 5 seconds. The time interval can bechanged depending on the capability of the measuring instrument or thelike.

In the first embodiment and the second embodiment described above, forthe ease of explanation, the invention according to the first embodimentand the invention according to the second embodiment have beenseparately described. However, these embodiments can also be combinedwith each other.

REFERENCE NUMERALS

-   2 filling machine-   6 feedback path-   7 product supply piping-   7 a upstream-side piping section-   7 b downstream-side piping section-   18 heating sterilization part

The invention claimed is:
 1. A sterilization process transition methodof switching from an SIP process to a product sterilization process in aproduct filling apparatus that includes product supply piping that feedsa product into a filling machine through a heating sterilization part,the SIP process being intended to sterilize the product supply piping inadvance before a product filling operation, and the productsterilization process being intended to sterilize the product to befilled, the method comprising: calculating an F value from temperaturedata and flowrate data on a fluid flowing in the heating sterilizationpart that are obtained from a plurality of temperature sensors andflowmeters disposed at arbitrary positions in the product fillingapparatus at predetermined time intervals, and adjusting the temperatureand flowrate at two or more of the plurality of predetermined positionsin the product filling apparatus from a set temperature and a setflowrate for the SIP process to a set temperature and a set flowrate forthe product sterilization process while preventing the F value frombecoming lower than a predetermined value.
 2. The sterilization steptransition method according to claim 1, wherein a pressure of theproduct passing through the heating sterilization part is higher than apressure of a heat source that heats the heating sterilization part or apressure of a coolant that cools the heating sterilization part.
 3. Thesterilization process transition method according to claim 1, whereinthe F value is calculated according toF=∫ _(t) ₀ ^(t) ¹ 10^((T-Tr)/Z) dt  [formula 1] where T denotes anarbitrary sterilization temperature (° C.), 10^((T-Tr)/Z) represents afatality rate at an arbitrary temperature T, Tr denotes a referencetemperature r (° C.), and Z denotes a Z value (° C.).
 4. A productfilling apparatus comprising product supply piping that feeds a productinto a filling machine through a heating sterilization part and asterilization process transition unit that switches from an SIP processto a product sterilization process, the SIP process being intended tosterilize the product supply piping in advance before a product fillingoperation, and the product sterilization process being intended tosterilize the product to be filled, wherein the product fillingapparatus further comprises a controller that calculates an F value fromtemperature data and flowrate data on a fluid flowing in the heatingsterilization part that are obtained from a plurality of temperaturesensors and flowmeters disposed at arbitrary positions in the productfilling apparatus at predetermined time intervals, and adjusts thetemperature and flowrate at two or more of the plurality ofpredetermined positions in the product filling apparatus from a settemperature and a set flowrate for the SIP process to a set temperatureand a set flowrate for any one of the product sterilization processeswhile preventing the F value from becoming lower than a predeterminedvalue.
 5. A method of cleaning and sterilizing a product fillingapparatus that includes product supply piping that feeds a product intoa filling machine through a heating sterilization part, the methodcomprising a CIP process of removing a remaining foreign matter from aproduct or the like on an interior of the product supply piping and anSIP process of sterilizing the interior of the product supply piping,wherein the CIP process and the SIP process are performed in sequencewithout an interruption between the CIP process and the SIP process, anda temperature of a heating sterilization part (UHT) raised and set inthe CIP process is not decreased but is further raised to a temperaturefor the SIP process, or a step of rinsing a cleaner, which is used inthe CIP process, is performed in transition from the CIP process to theSIP process while increasing the temperature at which the CIP processhas been performed to the temperature at which the SIP process is to beperformed.
 6. The method of cleaning and sterilizing a product fillingapparatus according to claim 5, wherein the SIP process ends when an Fvalue reaches a predetermined value, the F value being determined bysubstituting a value obtained from a thermometer in the product supplypiping into the following formula:F=∫ _(t) ₀ ^(t) ¹ 10^((T-121.1)/10) dt  [formula 2] where T denotes anarbitrary sterilization temperature (° C.), 10^((T-121.1)/10) representsa fatality rate at an arbitrary temperature T and corresponds to aheating duration (in minutes) at 121.1° C., which is a referencetemperature, and 10 denotes a Z value (° C.).
 7. The method of cleaningand sterilizing a product filling apparatus according to claim 5,wherein rinse water used to rinse the cleaner used in the CIP processhas a sterilization strength determined from a sterilization temperatureof the heating sterilization part and a flowrate in the heatingsterilization part.
 8. A method of cleaning and sterilizing a productfilling apparatus that includes product supply piping that feeds aproduct into a filling machine through a heating sterilization part, themethod comprising: a CIP process of removing a remaining foreign matterfrom a product or the like on an interior of the product supply pipingand an SIP process of sterilizing the interior of the product supplypiping, wherein the CIP process and the SIP process are performed insequence without an interruption between the CIP process and the SIPprocess; a first manufacturing step of performing a filling step offilling a container with the product while performing a productsterilization process after the SIP process; and a second manufacturingstep including the CIP process and the SIP process for manufacturing aproduct different from that manufactured in the first manufacturingstep, wherein the first manufacturing step and the second manufacturingstep are performed without reducing the temperature of the heatingsterilization part to be equal to or lower than a set temperature of theCIP process.
 9. The method of cleaning and sterilizing a product fillingapparatus according to claim 8, wherein the product supply piping isprovided with a filtering device that filters the product, and thefiltering device includes a switching step of switching between a firstfiltering device used in at least the first manufacturing step and asecond filtering device used in the second manufacturing step.
 10. Themethod of cleaning and sterilizing a product filling apparatus accordingto claim 9, wherein the first manufacturing step includes a cleaningstep of removing a remaining foreign matter on the second filteringdevice.
 11. A product filling apparatus that comprises product supplypiping that feeds a product into a filling machine through a heatingsterilization part and performs a CIP process of removing a remainingforeign matter from a product or the like on an interior of the productsupply piping and an SIP process of sterilizing the interior of theproduct supply piping, wherein the CIP process and the SIP process areperformed in sequence without an interruption between the CIP processand the SIP process, and a temperature of a heating sterilization part(UHT) raised and set in the CIP process is not decreased but is furtherraised to a temperature for the SIP process, or a step of rinsing acleaner, which is used in the CIP process, is performed in transitionfrom the CIP process to the SIP process while increasing the temperatureat which the CIP process has been performed to the temperature at whichthe SIP process is to be performed.